Valve leakage
I have a special problem with respect to valve that are used in offshore
oil and gas industry. A perticular manufacturer supply us valves
complying all the testing and specification requirement. But it is
observed the all those valves start passing within a very short span of
time. Therefore, I would like to know what are the things that is
required to review during finalisation of purchase specification.
It shall be of extreem help if you kindly help me in this regards.
Sounds like the valves passed factory leak tests, but quickly leaked
once put into service. If so, the problem is not that something was
missed during finalization of the purchase. The problem is that the
proper effort was not made before purchasing.
Keep in mind that
the factory tests are not intended to prove the valve is going to work
in a particular application. They are a quality check that verifies the
valve was manufactured and assembled correctly. Work needs to be done
upfront, before purchasing to verify the valve is the best choice and
will work in the application. You can request special testing that may
duplicate the service conditions (to the best that is practically
possible), and learn if the valve will work. But then it is far too
late and a waste of everyones time if it doesn't pass this test. It is
also much more expensive to do special tests. Just do the work upfront
before purchasing.
ANSI B16.104 is obsolete and withdrawn. See FCI 70-2 for Control Valve
Seat Leakage. This is much greater leakage than required by API STD
598.
It is common for new valves to meet the zero bubble
requirement in API STD 598 when new. Sand was already mentioned. The
nasty rusty hydrostatic testing fluid is often left in the lines for a
prolonged period leaving scale and such in the seats. Such practices
cause the valves to leak even during the initial startup.
Some
attempts to fix the problem include adjusting the limit stops to get a
fresh piece of the seat into service in addition to the lubrication
tricks.One trick not mentioned is to use a plug valve.
Nonlubricated
valves have a (usually) PTFE sleeve for sealing. The plug has a 2 degree
taper. If you catch 'em leaking, there is an adjustment to drive the
plug farther into the taper, restoring the shutoff. Nonlubricated plug
valves are available thru ASME class 600, Lubricated plug valves are
available for higher pressures. Ball valves are hard to turn, but
comparatively, plug valves are HARD to turn. Bring a long, long,
cheater bar.
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